PTFE composite multi-layer material

ABSTRACT

A composite multi-layer material may generally comprise a d-PTFE material combined with an open structured material (either resorbable or non-resorbable) creating a composite multi-layer material. Attachment of the layers may be accomplished by stitching layers of material, exertion of hydraulic or other pressure, application of a biocompatible adhesive or heat, or some combination of the foregoing. Use of a d-PTFE, unexpanded material has multiple alternative uses, including without limitation, placement on the visceral side of a hernia that may minimize or even eliminate the incidence of abdominal adhesions. Alternatively, the material may be used to create tubing sufficient as a graft for treating abdominal aortic aneurysms.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 11/354,272, filed Feb. 14, 2006 (U.S. Pat. No. 7,789,888),which claimed the benefit of U.S. Provisional Application Ser. No.60/653,069, filed Feb. 14, 2004, entitled “COMPOSITE PTFE RECONSTRUCTIVEMESH,” and both applications are incorporated herein by reference forall purposes. The present application is related to U.S. Pat. No.5,957,690, issued Sep. 28, 1999, which is incorporated herein byreference and U.S. patent application Ser. No. 10/947,066, filed Sep.21, 2004, which is incorporated herein by reference.

FIELD OF THE INVENTION

Aspects of the present invention relate generally to implantable medicalproducts and more particularly to a high density unexpanded, unsinteredpolytetrafluoroethylene (d-PTFE) for use in tissue repair,reconstruction, grafting and regeneration.

BACKGROUND

Traditional repair, reconstruction and grafting of soft tissue andvascular tissue require techniques utilizing a reconstructive materialor vascular prostheses. For instance, in hernia repair, currentlymarketed mesh devices generally include a laminated expandedpolytetrafluoroethylene (e-PTFE) structure, using e-PTFE laminated toone or more sheets of e-PTFE or to a polypropylene mesh. The rationalefor using e-PTFE is to minimize post-operative abdominal adhesions tothe mesh. The currently marketed products use e-PTFE on the visceralside (bowel side) and an open pore material such as polypropylene meshon the fascia or muscular side. The open structured polypropylenematerial is believed to promote tissue in-growth into the material, thuscreating a strong reconstruction.

Postoperative adhesions continue to present significant clinicalproblems, however, and result in morbidity, mortality, and increasedcost. With over 700,000 hernia operations per year, the frequency ofsecondary procedures to eliminate or otherwise to treat abdominaladhesions is generally in a range of about 50-60%, sometimes higher. Nocause for these adhesions is known. While products employing e-PTFEattempt to minimize the incidence of adhesions as a result of thelimited porosity and biocompatible nature of the material, the continuedhigh level of adhesion incidence is representative of a clear deficiencyin currently marketed technology.

Currently, surgery is the primary option for hernia repair and there aretwo primary methods of repair: tension repair and tension-free repair.For many years, tension repair was the only method for treating hernias.Tension repair involves incising the abdomen, pushing the protrudingtissue back into the abdominal cavity and stitching the incision. Itshould be noted that while effective, this method causes severe patientdiscomfort and requires substantial recovery time relative to moremodern repair methods.

Tension-free surgery is more commonly used in hernia repair today. Itrequires less time for recovery vis-à-vis the tension repair method. Thetension-free repair method involves incising the abdomen, pushing theprotruding tissue back into place and placing a piece of mesh eitherover or under the defect, which is then sutured into place. The meshprevents the tissue from protruding through the hole.

Some hernia repair devices use porcine small intestinal submucosa toprovide a scaffold for host cells to replace and repair damaged tissue.Once implanted into the hernia defect, host tissue cells and bloodvessels colonize the graft and allow for site-specific tissueremodeling. The porcine small intestine tissue is gradually replaced byhost tissue. However, the use of animal tissue poses both host immuneresponse tissue rejection problems and potential for transmitted diseasefrom animal to human.

Many types of mesh currently on the market are subject to shrinkage ormigration. As a result, use of these products can lead to pain and bowelcomplications, which in turn may lead to infection.

Vascular repair and requires the use of graft tubing. For instance,abdominal aortic aneurysm repair traditionally requires a large incisionin the abdominal wall from just below the sternum to the top of thepubic bone. After the intestines and internal organs of the abdomen arepulled aside, the aorta is clamped and the aneurysm cut open. Afterremoving any damaged tissue, an aortic graft is sewn into the healthyaortic tissue both above and below the weakened area to create a bridgefor proper blood flow. Typically, after the graft has been sewn intoplace, the tissue remaining from the aneurysm sac is loosely sewn overthe new graft to prevent the new graft from rubbing against theintestine.

An alternative abdominal aortic aneurysm repair procedure uses an x-rayimaging device to deliver catheter (tube) containing a graft. Thecatheter is inserted into a blood vessel in the groin and guided to theaorta. Once in the aorta, a balloon at the catheter's tip is inflatedand the graft tubing is expanded to a diameter necessary to precludeblood from flowing into the aneurysm. The catheter is removed bydeflating the balloon and withdrawing it from the leg. The graft permitsthe flow of blood through the aorta to the arteries in the pelvis andlower extremities while bypassing the aneurysm.

SUMMARY

In accordance with some embodiments of a composite multi-layer material,d-PTFE may be combined with an open structured material (eitherresorbable or non-resorbable) creating a composite multi-layerstructure. It will be appreciated that such attachment may beaccomplished by stitching layers of material, exertion of hydraulic orother pressure, application of a biocompatible adhesive or heat, or somecombination of the foregoing. One or more combinations may be used inthe laminating process. A composite multi-layer material constructed andoperative in accordance with the present disclosure may have utility inapplications related to the reconstruction of soft tissue defects of thechest and abdomen.

Because d-PTFE has no substantially defined internodal distance and canbe manufactured with significantly less porosity than e-PTFE, andbecause it has exhibited no tendency to form adhesions when used in oraland maxillofacial surgical applications, the use of a d-PTFE, unexpandedmaterial on the visceral side of a soft tissue composite multi-layermaterial may minimize or even eliminate the incidence of abdominaladhesions and post-operative complications as compared to existingdevices. In addition, it will be appreciated that the material may beused to create a tube for use as a vascular prosthetic capable ofpermitting blood flow through the interior of the graft while providingan open structured material on the exterior to permit tissuecolonization.

The term sintered is a term well known in the art and is used hereinconsistent with that understanding. The term unsintered is used hereinto describe PTFE polymer that has not been subjected to the sinteringprocess. Unsintered PTFE is substantially unexpanded and contains nosubstantially defined internodal distance, which substantially reducesits porosity relative to e-PTFE. The limited porosity of the unsintered,substantially unexpanded PTFE substantially reduces tissue adhesions tothe d-PTFE or migration of tissue into the d-PTFE. However, the limitedporosity allows for the passage of ions and other small moleculesnecessary for cellular nourishment and waste transport.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a simplified partial perspective diagram illustrating oneembodiment of a composite multi-layer material.

FIG. 2 is an exploded partial perspective diagram illustrating oneembodiment of a composite multi-layer material.

FIG. 3 is an illustration of the devices that can be formed from thecomposite multi-layer material.

DETAILED DESCRIPTION

Turning now to the drawing figures, it will be appreciated that FIG. 1is a simplified partial perspective diagram, and FIG. 2 is an explodedpartial perspective diagram, illustrating one embodiment of a compositemulti-layer material. It will be appreciated that FIG. 3 is anillustration of embodiments of the devices that can be formed from thecomposite multi-layer material.

In accordance with some embodiments of a composite multi-layer material,at least a portion of a layer including d-PTFE 32 may be combined withor attached to at least a portion of a layer including an openstructured material 30 to create a composite multi-layer material withan attachment region 31 between the layers. The interface between thelayers may include attachment of partial areas of the layers or theinterface may include attachment encompassing the entire surface of theinterfaced layers.

In accordance with some embodiments of a composite multi-layer material,the composite multi-layer material may be formed into a flat structurewith a layer including an open structured material, a layer includingd-PTFE and an interface between the layers that may include attachmentof a portion of the layers or may include an attachment between thelayers encompassing the entire surface of the interfaced layers. Variousdifferent devices comprising the flat structured composite multi-layermaterial can be used in the repair of soft tissue. In many embodiments,the soft tissue for repair is in the chest. In many embodiments, thesoft tissue for repair is in the abdomen.

In accordance with some embodiments of a composite multi-layer material,the composite multi-layer material may be formed into a tube structurehaving a inner layer including d-PTFE 35, an outer layer including anopen structured material 33 and an interface 34 between the layers thatmay include attachment of a portion of the layers or may include anattachment encompassing the entire surface of the interfaced layers.Various different devices comprising the tube structured compositemulti-layer material can be used in the repair of vascular tissue.Various different devices comprising the tube structured compositemulti-layer material can be used as grafts for vascular tissue. In manyembodiments, the vascular tissue for repair or grafting is in the chest.In certain embodiments, the vascular tissue for repair or graftingincludes the vasculature including or surrounding the aorta. In certainembodiments, the vascular tissue for repair or grafting includes thecoronary vasculature. In other embodiments, the vascular tissue forrepair is in the abdomen. In other embodiments, the vascular tissue forrepair is in the head and neck. In other embodiments, the vasculartissue for repair is in the arms and legs. In other embodiments, thevascular tissue for repair is in the groin area.

It will be appreciated that such attachment of the layers creating aninterface may be accomplished by stitching layers of material, exertionof hydraulic or other pressure, application of a biocompatible adhesiveor heat, or some combination of the foregoing. One or more combinationsmay be used in the attachment process. A composite multi-layer materialconstructed and operative in accordance with the present disclosure mayhave utility in applications related to the reconstruction of softtissue defects of the chest and abdomen.

Because d-PTFE has no substantially defined internodal distance and canbe manufactured with significantly less porosity than e-PTFE, andbecause it has exhibited no tendency to form adhesions when used in oraland maxillofacial surgical applications, the use of a d-PTFE, unexpandedmaterial on the visceral side of a soft tissue composite multi-layermaterial may minimize or even eliminate the incidence of abdominaladhesions and post-operative complications as compared to existingdevices. In addition, it will be appreciated that the material may beused to create a tube for use as a vascular prosthetic capable ofpermitting blood flow through the interior of the graft while providingan open structured material on the exterior to permit tissuecolonization.

The terms “sintered” and “sintering process” are terms well known in theart and are used herein consistent with their understanding by thoseskilled in the art. Upon sintering, PTFE may be expanded to obtain adesired internodal distance and porosity. The term unsintered is usedherein to describe PTFE that has not been subjected to the sinteringprocess. Unsintered PTFE is substantially unexpanded and contains nosubstantially defined internodal distance, which substantially reducesits porosity relative to e-PTFE. The limited porosity of the unsintered,substantially unexpanded d-PTFE substantially reduces tissue adhesionsto the d-PTFE or migration of tissue or cells into the d-PTFE. However,despite its limited porosity, unsintered and unexpanded d-PTFE allowsfor the passage of ions and other small molecules necessary for cellularnourishment and waste transport.

A composite multi-layer material constructed and operative in accordancewith the present disclosure may have substantial, uniform strength inall directions, and may have at least one smooth side (e.g., comprisingthe d-PTFE layer to be exposed on the visceral side of the materialduring use). The composite multi-layer material may be constructed usingd-PTFE having a hydrophobic, hydrophilic, textured or non-texturesurface, combined with, or attached to, one or more open structuredmaterials including unexpanded PTFE non-woven flatsheet; unexpanded PTFEwoven materials; unexpanded PTFE mesh; expanded PTFE non-wovenflatsheet; expanded PTFE woven materials, expanded PTFE mesh;polypropylene mesh; polypropylene woven materials and non-wovenmaterials; resorbable polymer non-woven; resorbable polymer wovenmaterials; resorbable polymer mesh; non-resorbable polymer non-wovenmaterials; non-resorbable woven materials; non-resorbable mesh, or somecombination of the foregoing. As noted briefly above, various techniquessuch as stitching, application of pressure, heat, adhesives, and thelike, may be employed to effectuate the attachment of materials to forman interface between them. Such techniques may be application specific,and may vary in accordance with the type of materials to be attached,desired rigidity of the composite multi-layer material, and otherfactors. In operation, the composite multi-layer material may be suturedinto place due to the nature of the material; additionally oralternatively, adhesives, staples, or other cooperating structuralelements may be employed to place and to retain composite multi-layermaterial.

As noted above, conventional devices and techniques are generallydeficient to the extent that they fail to contemplate use of highdensity or unexpanded PTFE in a composite multi-layer material for softtissue repair. While laminated e-PTFE materials have been employed forsoft tissue repair, the e-PTFE material is generally characterized bysubstantial porosity and defined internodal distances. In this context,internodal distance is a measurement used to describe the distancebetween the nodes and fibrils, a characteristic unique to e-PTFE only,and fundamentally describes the porosity or physical characteristics ofthe pores within the material. In contrast, the structure of the d-PTFEmaterial set forth herein has no measurable, repeatable internodaldistance as is commonly present with materials manufactured from e-PTFE.

Specifically, the d-PTFE material which may be implemented as the basematerial is a high density PTFE with a density in a range of about 1.2grams/cc to about 2.3 grams/cc; for some applications, the density ofd-PTFE may be in a range of about 1.45 grams/cc to about 1.55 grams/cc.As set forth above, the d-PTFE material may be unsintered and unexpandedhaving a nominal pore channel size of less than about 5 micrometers. Insome embodiments, the unsintered, unexpanded d-PTFE may have a nominalpore channel size of less than 2 micrometers. In some embodiments, theunsintered, unexpanded d-PTFE may have a nominal pore channel size ofless than 0.5 micrometers. In some embodiments, the unsintered,unexpanded d-PTFE may have a nominal pore channel size of less than 0.2micrometers. This small pore channel size may allow a compositemulti-layer material employing d-PTFE to exhibit superior functionalcharacteristics, resulting clinically in reduced host response(inflammation), soft tissue in-growth, and resultant adhesions.

Several features and aspects of the present invention have beenillustrated and described in detail with reference to particularembodiments by way of example only, and not by way of limitation. Thoseof skill in the art will appreciate that alternative implementations andvarious modifications to the disclosed embodiments are within the scopeand contemplation of the present disclosure.

What is claimed is:
 1. A method of treating a patient in need of tissuerepair, comprising contacting the tissue in need of repair with acomposite multi-layer material comprising: a first layer formed fromunsintered substantially unexpanded polytetrafluoroethylene polymer andhaving a density in a range of about 1.2 gm/cc to about 2.3 gm/cc andhaving a plurality of pores having a nominal channel size of less than 5micrometers; and a second layer formed from an open structured material,wherein surfaces of the first and second layers are attached at a commoninterface, wherein the first and second layers are attached by stitchingat least a portion of said first layer to at least a portion of saidsecond layer.
 2. The method of claim 1, wherein the nominal channel sizeis less than 2 micrometers.
 3. The method of claim 1, wherein thenominal channel size is less than 0.5 micrometers.
 4. The method ofclaim 1, wherein the nominal channel size is less than 0.2 micrometers.5. The method of claim 1, wherein the first layer has a hydrophobicsurface.
 6. The method of claim 1, wherein the first layer has ahydrophilic surface.
 7. The method of claim 1, wherein the openstructured material includes unexpanded PTFE.
 8. The method of claim 7,wherein the open structured material forms a non-woven flatsheet.
 9. Themethod of claim 7, wherein the open structured material forms a wovenflatsheet.
 10. The method of claim 7, wherein the open structuredmaterial forms a mesh.
 11. The method of claim 1, wherein the openstructured material includes polypropylene.
 12. The method of claim 11,wherein the open structured material forms a non-woven flatsheet. 13.The method of claim 11, wherein the open structured material forms awoven flatsheet.
 14. The method of claim 11, wherein the open structuredmaterial forms a mesh.
 15. The method of claim 11, wherein the openstructured material includes a resorbable polymer.
 16. The method ofclaim 15, wherein the open structured material forms a non-wovenflatsheet.
 17. The method of claim 15, wherein the open structuredmaterial forms a woven flatsheet.
 18. The method of claim 15, whereinthe open structured material forms a mesh.
 19. The method of claim 1,wherein the open structured material comprises a non-resorbable polymer.20. The method of claim 19, wherein the open structured material forms anon-woven flatsheet.
 21. The method of claim 19, wherein the openstructured material forms a woven flatsheet.
 22. The method of claim 19,wherein the open structured material forms a mesh.
 23. The method ofclaim 1, wherein the first and second layers are attached using abiocompatible adhesive.
 24. The method of claim 1, wherein the first andsecond layers are attached using heat.
 25. The method of claim 1,wherein said composite multi-layer material forms a tube structurewherein said first layer forms the tube's interior surface and saidsecond layer forms the tube's exterior surface.
 26. The method of claim1, wherein the polytetrafluoroethylene polymer of the first layer has adensity in the range of 1.45 gm/cc to 1.55 gm/cc.
 27. The method ofclaim 1, wherein the tissue in need of repair comprises a hernia.